EP2287137A2 - Verfahren zur Herstellung von Umgebungsschutzschichten mit sinterungsfördernden Zusätzen - Google Patents

Verfahren zur Herstellung von Umgebungsschutzschichten mit sinterungsfördernden Zusätzen Download PDF

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EP2287137A2
EP2287137A2 EP10171526A EP10171526A EP2287137A2 EP 2287137 A2 EP2287137 A2 EP 2287137A2 EP 10171526 A EP10171526 A EP 10171526A EP 10171526 A EP10171526 A EP 10171526A EP 2287137 A2 EP2287137 A2 EP 2287137A2
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Prior art keywords
slurry
layer
compliant
transition
rare earth
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French (fr)
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EP2287137A3 (de
EP2287137B1 (de
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Glen Harold Kirby
Brett Allen Boutwell
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General Electric Co
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General Electric Co
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions

Definitions

  • Embodiments described herein generally relate to methods for making environmental barrier coatings using sintering aids suitable for use with high temperature components.
  • Ceramic matrix composites are a class of materials that consist of a reinforcing material surrounded by a ceramic matrix phase. Such materials, along with certain monolithic ceramics (i.e. ceramic materials without a reinforcing material), are currently being used for higher temperature applications. These ceramic materials are lightweight compared to superalloys yet can still provide strength and durability to the component made therefrom. Therefore, such materials are currently being considered for many gas turbine components used in higher temperature sections of gas turbine engines, such as airfoils (e.g. turbines, and vanes), combustors, shrouds and other like components that would benefit from the lighter-weight and higher temperature capability these materials can offer.
  • airfoils e.g. turbines, and vanes
  • combustors e.g. turbines, and vanes
  • CMC and monolithic ceramic components can be coated with environmental barrier coatings (EBCs) to protect them from the harsh environment of high temperature engine sections.
  • EBCs can provide a dense, hermetic seal against the corrosive gases in the hot combustion environment, which can rapidly oxidize silicon-containing CMCs and monolithic ceramics. Additionally, silicon oxide is not stable in high temperature steam, but rather, can be converted to volatile (gaseous) silicon hydroxide species. Thus, EBCs can help prevent dimensional changes in the ceramic component due to such oxidation and volatilization processes.
  • plasma spray and vapor deposition i.e. chemical vapor deposition, CVD, and electron beam physical vapor deposition, EBPVD
  • EBPVD electron beam physical vapor deposition
  • Embodiments herein generally relate to methods for making an environmental barrier coating using a sintering aid comprising: applying a bond coat layer to the ceramic component; combining at least an organic solvent, a primary transition material comprising a rare earth disilicate, or a doped rare earth disilicate, and at least one slurry sintering aid to produce a transition layer slurry; combining at least an organic solvent, and a primary outer material comprising a rare earth monosilicate or a doped rare earth monosilicate to produce an outer layer slurry; combining at least an organic solvent, and a primary compliant material comprising BSAS or a rare earth doped BSAS to produce a compliant layer slurry; applying at least the transition layer slurry, and any one or more of the outer layer slurry, and the compliant layer slurry to the component; and sintering the component to produce the environmental barrier coating having at least the bond coat layer, a transition layer and any of an outer layer or a compliant layer wherein
  • Embodiments herein also generally relate to methods for making an environmental barrier coating using a sintering aid comprising: applying a bond coat layer to the ceramic component; combining at least an organic solvent, a primary transition material comprising a rare earth disilicate, or a doped rare earth disilicate, and two slurry sintering aids to produce a transition layer slurry; combining at least an organic solvent, and a primary outer material comprising a rare earth monosilicate or a doped rare earth monosilicate to produce an outer layer slurry; combining at least an organic solvent, and a primary compliant material comprising BSAS or a rare earth doped BSAS to produce a compliant layer slurry; applying at least the transition layer slurry, and any one or more of the outer layer slurry, and the compliant layer slurry to the component; and sintering the component to produce the environmental barrier coating having at least the bond coat layer, a transition layer and any of an outer layer or a compliant layer wherein
  • Embodiments described herein generally relate to methods for making environmental barrier coatings using sintering aids suitable for use with high temperature components.
  • the EBCs described herein comprise solvent based slurries having sintering aids, which can lower the sintering temperature, thereby promoting the formation of dense EBC layers that can act as a hermetic seal to protect the underlying component from corrosion from the gases generated during high temperature combustion without damaging the component through exposure to high sintering temperatures, as explained herein below.
  • CMCs refers to silicon-containing matrix and reinforcing materials.
  • Some examples of CMCs acceptable for use herein can include, but should not be limited to, materials having a matrix and reinforcing fibers comprising silicon carbide, silicon nitride, and mixtures thereof.
  • monolithic ceramics refers to materials comprising silicon carbide, silicon nitride, and mixtures thereof.
  • CMCs and monolithic ceramics are collectively referred to as "ceramics.”
  • barrier coating(s) can refer to environmental barrier coatings (EBCs).
  • EBCs environmental barrier coatings
  • the barrier coatings herein may be suitable for use on "ceramic component,” or simply “component” 10 found in high temperature environments (e.g. operating temperatures of above 2100°F (1149°C)), such as those present in gas turbine engines.
  • ceramic components can include, for example, combustor components, turbine blades, shrouds, nozzles, heat shields, and vanes.
  • EBC 12 may comprise a coating system including various combinations of the following: a bond coat layer 14, an optional silica layer 15, at least one transition layer 16, an optional compliant layer 18, an optional intermediate layer 22, and an optional outer layer 20, as shown generally in FIG. 1 and as set forth herein below.
  • silicide may include rare earth (Ln) silicides, chromium silicide (e.g. CrSi 3 ), niobium silicide (e.g. NbSi 2 , NbSi 3 ), molybdenum silicide (e.g. MoSi 2 , MoSi 3 ), tantalum silicide (e.g.TaSi 2 , TaSi 3 ), titanium silicide (e.g. TiSi 2 , TiSi 3 ), tungsten silicide (e.g. WSi 2 , W 5 Si 3 ), zirconium silicide (e.g. ZrSi 2 ,)), hafnium silicide (e.g. HfSi 2 ),
  • Ln silicides chromium silicide (e.g. CrSi 3 ), niobium silicide (e.g. NbSi 2 , NbSi 3 ), molybdenum sil
  • rare earth represented “(Ln)” refers to the rare earth elements of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), and mixtures thereof.
  • Silica layer 15 can be amorphous or crystalline, and have an initial thickness of from about 0.0 mils to about 0.2 mils. However, the thickness of silica layer 15 can increase over time. Specifically, the silicon in bond coat layer 14 can oxidize slowly during the service life of the EBC to gradually increase the thickness of silica layer 15. This oxidation of bond coat 14 can protect the underlying ceramic component from oxidation since the bond coat is oxidized rather than the ceramic component. Silica layer 15 can, in some embodiments, also be doped with a doping composition, as defined herein below, due to diffusion of the sintering aid into the silica layer.
  • a doping composition as defined herein below
  • primary transition material refers to a rare earth disilicate (Ln 2 Si 2 O 7 ), or a doped rare earth disilicate.
  • doped rare earth disilicate refers to Ln 2 Si 2 O 7 doped with a "doping composition” selected from the group consisting of iron (Fe), aluminum (Al), titanium (Ti), gallium (Ga), nickel (Ni), boron (B), an alkali, an alkali-earth, and Lnb rare earths, as defined herein below.
  • Any doping composition present in the primary material should correspond to the doping composition contained in any secondary material present (e.g. Fe-doped Ln 2 ShO 7 with Fe 2 O 3 secondary material; Ti-doped Ln 2 ShO 7 with TiO 2 secondary material; or Ni-doped Ln 2 SiO 7 with rare earth nickel oxide secondary material, for example).
  • any secondary material present e.g. Fe-doped Ln 2 ShO 7 with Fe 2 O 3 secondary material; Ti-doped Ln 2 ShO 7 with TiO 2 secondary material; or Ni-doped Ln 2 SiO 7 with rare earth nickel oxide secondary material, for example.
  • Each transition layer 16 may have a thickness of from about 0.1 mils to about 40 mils, and may be made and applied to the underlying layer as set forth below. In one embodiment, there may be more than one transition layer present. In such instances, each transition layer may comprise the same or different combination of primary transition materials and secondary materials. Transition layer 16 may have a porosity level of from 0% to about 15% by volume of the transition layer, and in another embodiment, from about 0.01% to about 15% by volume of the transition layer.
  • outer layer 20 may have a thickness of from about 0.1 mils to about 3 mils, and may be made and applied to the underlying layer as set forth below. In one embodiment, outer layer 20 may have a porosity level of from 0% to about 30% by volume of the outer layer, and in another embodiment, from about 0.01% to about 30% by volume of the outer layer, and in another embodiment, from about 0.01% to about 15% by volume of the outer layer. In some embodiments, outer layer 20 can comprise cracks therein at a density of up to about 10 cracks/mm that can form during operation due to thermal expansion anisotropy.
  • Lnb rare earth metal refers to a sub-set of rare-earth metals having a melting point below at least about 1450°C including lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, and ytterbium.
  • the sub-set can include only those rare earth elements having a melting point below about 1350°C including lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, and ytterbium.
  • the Lnb rare earth metal can be utilized with SiC-SiC CMCs having an operation limit of about 1357°C.
  • alkaline earth can refer to magnesium (Mg), calcium (Ca), strontium (Sr), and barium (Ba).
  • alkali refers to lithium (Li), potassium (K), and sodium (Na).
  • Iron silicates can include compounds such as Fe 2 SiO 4 , and glasses of rare earth iron silicates.
  • Rare earth iron oxides can include compounds such as garnets (Ln 3 Fe 5 O 12 ), monoclinic ferrites (Ln 4 Fe 2 O 9 ) and perovskites (LnFeO 3 ).
  • “Rare-earth aluminates” can include compounds such as garnets (Ln 3 Al 5 O 12 ), monoclinic aluminates (Ln 4 Al 2 O 9 ), and perovskites (LnAlO 3 ).
  • "Rare earth aluminates” can include glassy materials comprised of about 35-50 wt% Ln 2 O 3 , about 15-25 wt% Al 2 O 3 , and about 25-50 wt% SiO 2 .
  • Ring-earth titanates can include compounds such as Ln 2 Ti 2 O 7 (pyrochlore) and Ln 2 TiO 5 -
  • Ring-earth gallates can include compounds such as garnets (Ln 3 Ga 5 O 12 ), monoclinic gallates (Ln 4 Ga 2 O 9 ), perovskites (LnGaO 3 ), and Ln 3 GaO 6 .
  • Nickel silicates can include compounds such as Ni 2 SiO 4 .
  • “Borosilicate glass” can refer to any amorphous material containing up to about 15% by weight boron oxide (B 2 O 3 ), up to about 10% alkali oxide selected from the group consisting of sodium (Na 2 O), potassium (K 2 O), lithium (Li 2 O), or any combinations of thereof, up to about 10% alumina (Al 2 O 3 ), and a balance of silica (SiO 2 ).
  • B 2 O 3 boron oxide
  • alkali oxide selected from the group consisting of sodium (Na 2 O), potassium (K 2 O), lithium (Li 2 O), or any combinations of thereof, up to about 10% alumina (Al 2 O 3 ), and a balance of silica (SiO 2 ).
  • Alkaline earth silicates can include compounds such as Mg 2 SiO 4 , MgSiO 3 , Ca 2 SiO 4 , Ca 3 SiO 5 , Ca 3 Si 2 O 7 , CaSiO 3 , Ba 2 SiO 4 , BaSiO 3 , Ba 2 Si 3 O 8 , BaSi 2 O 5 , Sr 2 SiO 4 , and SrSiO 3 .
  • Alkali earth rare earth oxides can include compounds such as BaLn 2 O 4 , Mg 3 Ln 2 O 6 , SrLn 2 O 4 , and Sr 2 Ln 2 O 5
  • Alkaline earth rare earth silicates can include oxyapatite materials (i.e. Ae 2 Ln 8 Si 6 O 26 ).
  • compliant layer 18 may include from about 85% to about 100% by volume of the compliant layer of a primary compliant material and up to about 15% by volume of the compliant layer of a secondary compliant material, and in one embodiment from about 85% to about 99% by volume of the compliant layer of a primary compliant material and from about 1% to about 15% by volume of the compliant layer of the secondary compliant material. In another embodiment, compliant layer 18 may comprise 100% by volume of the compliant layer of a primary compliant material wherein the primary outer material may be doped with a rare earth element.
  • primary compliant material refers to BSAS, or a rare earth doped BSAS
  • secondary compliant material refers to Ln 2 O 3 , Ln 2 Si 2 O 7 , Ln 2 SiO 5 , Ln 3 Al 5 O 12 , Al 2 O 3 , mullite, and combinations thereof.
  • Compliant layer 20 may have a thickness of from about 0.1 mils to about 40 mils, and may be made and applied as set forth below.
  • compliant layer 18 may have a porosity level of from 0% to about 30% by volume of the compliant layer, and in another embodiment, from about 0.01% to about 30% by volume of the compliant layer, and in another embodiment, from about 0.01% to about 15% by volume of the compliant layer.
  • Intermediate layer 22 can comprise the previously defined primary outer materials of rare earth monosilicate or doped rare earth monosilicate. Similar to the silica layer, intermediate layer 22 can form during the service life of the EBC. More specifically, high temperature steam penetrates the outer layer 20, and as the steam reacts with the primary transition material of the transition layer to volatilize SiO 2 , intermediate layer 22 can form.
  • the EBC systems described herein may include in one embodiment, component 10, bond coat layer 14, and transition layer 16; in another embodiment, component 10, bond coat layer 14, transition layer 16, and outer layer 20; in another embodiment, component 10, bond coat layer 14, transition layer 16, compliant layer 18, and outer layer 20; in another embodiment, component 10, bond coat layer 14, transition layer 16, compliant layer 18, transition layer 16, and outer layer 20; in another embodiment, component 10, bond coat layer 14, silica layer 15, and transition layer 16; in another embodiment, component 10, bond coat layer 14, silica layer 15, transition layer 16, and outer layer 20; in another embodiment, component 10, bond coat layer 14, silica layer 15, transition layer 16, compliant layer 18, and outer layer 20; in another embodiment, component 10, bond coat layer 14, silica layer 15, transition layer 16, compliant layer 18, transition layer 16, and outer layer 20; in another embodiment, component 10, bond coat layer 14, silica layer 15, transition layer 16, compliant layer 18, transition layer 16, and outer layer 20; in another embodiment, component 10, bond coat layer 14, transition layer 16, intermediate layer 22, and outer layer 20; in another embodiment, component 10, bond coat layer 14, silica layer
  • the EBC system may comprise component 10, bond coat layer 14, transition layer 16, and compliant layer 18; in another embodiment, component 10, bond coat layer 14, silica layer 15, transition layer 16, and compliant layer 18.
  • Such embodiments can be suitable for use in environments having a temperature of up to about 1538°C (2800°F).
  • the EBC can be made and applied in accordance with the description below.
  • Bond coat layer 14 may be applied by plasma spray processes, chemical vapor deposition processes, electron beam physical vapor deposition processes, dipping in molten silicon, sputtering processes, and other conventional application processes known to those skilled in the art.
  • intermediate layer 22 can also form during the service life of the EBC when high temperature steam reacts with transition layer 16, as previously described.
  • the manufacturing and application processes for transition layer 16, compliant layer 18 and outer layer 20 can consist of a solvent based slurry deposition cycle including sintering aids to lower the temperature needed to densify the layers.
  • the slurry deposition cycle can generally include slurry formation, slurry application, drying, and sintering, with optional masking, leveling, sintering aid infiltration, mask removal, and binder burnout steps, as set forth below.
  • slurries of varying compositions can be used to make EBC layers of varying composition and that multiple slurry deposition cycles can be used to build up the total thickness of a particular layer.
  • Each layer can have the thickness set forth previously with the average thickness per slurry deposition cycle depending primarily on the slurry solids loading, sintering aid concentration, and number of dip, spray, or paint passes.
  • organic solvent refers to methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, octanol, nonanol, decanol, dodecanol, acetone, methyl isobutyl ketone (MIBK), methyl ethyl ketone (MEK), toluene, ethylbenzene, propyl benzene, methoxybenzene, heptane, octane, nonane, decane, xylene, mineral spirits, naptha (such as VM&P naptha), tetrahydrofuran, ethers, and combinations thereof.
  • MIBK methyl isobutyl ketone
  • MEK methyl ethyl ketone
  • toluene ethylbenzene
  • propyl benzene propyl benzene
  • Disposant can refer to polyacrylic acid, polyacrylic acid-polyethylene oxide copolymers, polymethacrylic acid, polyethylenimine, phosphate esters, menhaden fish oil, polyethylene oxide, polysilazane, and combinations thereof.
  • Polymer can refer to ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol glycerol, glycerin, polyethylene glycol, dibutyl phthalate, Bis(2-ethylhexyl) phthalate, Bis(n-butyl)phthalate, Butyl benzyl phthalate, Diisodecyl phthalate, Di-n-octyl phthalate, Diisooctyl phthalate, Diethyl phthalate, Diisobutyl phthalate, Di-n-hexyl phthalate, Di(propylene glycol) dibenzoate, Di(ethylene glycol) dibenzoate, tri(ethylene glycol) dibenzoate, and combinations thereof.
  • slurry sintering aid can refer to sintering aid compositions suitable for inclusion in the slurry.
  • a slurry sintering aid selected from iron oxide, gallium oxide, aluminum oxide, nickel oxide, titanium oxide, boron oxide, and alkaline earth oxides; carbonyl iron; iron metal, aluminum metal, boron, nickel metal, hydroxides including iron hydroxide, gallium hydroxide, aluminum hydroxide, nickel hydroxide, titanium hydroxide, alkaline earth hydroxides; carbonates including iron carbonate, gallium carbonate, aluminum carbonate, nickel carbonate, boron carbonate, and alkaline earth carbonates; oxalates including iron oxalate, gallium oxalate, aluminum oxalate, nickel oxalate, titanium oxalate; and
  • the "slurry sintering aid" may include rare earth nitrate, rare earth acetate, rare earth chloride, rare earth oxide, ammonium phosphate, phosphoric acid, polyvinyl phosphoric acid, and combination thereof.
  • the slurry can comprise from about 0 wt% to about 59.3 wt%, and in one embodiment from about 0.01 wt% to about 59.3 wt%, of an Lnb metal slurry sintering aid as defined previously herein, and from about 0 wt% to about 20.6 wt%, and in one embodiment from about 0.01 wt% to about 20.6 wt%, of a SiO 2 slurry sintering aid.
  • the Lnb and SiO 2 content can be held such that the mole ratio of Lnb to SiO 2 is about 1 to 1 for slurries containing rare earth disilicate primary transition material, and about 2 to 1 for slurries containing rare earth monosilicate primary outer material.
  • solvent-soluble iron salts can include ethoxide, iron 2,4-pentanedionate, and iron tetramethylheptanedionate
  • solvent-soluble gallium salts can include gallium 8-hydroxyquinolinate, gallium 2,4-pentanedionate, gallium ethoxide, gallium isopropoxide, and gallium 2,2,6,6-tetramethylheptanedionate
  • solvent-soluble aluminum salts can include butoxide, aluminum di-s-butoxide ethylacetoacetate, aluminum diisopropoxide ethylacetoacetate, aluminum ethoxide, aluminum ethoxyethoxyethoxide, aluminum 3,5-heptanedionate, aluminum isopropoxide, aluminum 9-octadecenylacetoacetate diisopropoxide, aluminum 2,4-pentanedionate, aluminum pentanedionate bis(ethylacetoa)
  • Thickener refers to polyvinyl butyral, polyvinyl acetate, poly(isobutyl methacrylate), poly[(n-butyl methacrylate-co-isobutyl methacrylate)], methyl methacrylate copolymers, ethyl methacrylate copolymers, poly methyl methacrylate, polyethyl methacrylate, polyvinylpyroline, ethyl cellulose, nitrocellulose, and other solvent soluble cellulose derivatives, and combinations thereof.
  • “Surfactant” refers to compositions selected from the group consisting of fluorocarbons, dimethylsilicones, and ethoxylated acetylenic diol chemistries (e.g. commercial surfactants in the Surfynol® series such as Surfynol® 420 and 502 (Air Products and Chemicals, Inc.)), and combinations thereof.
  • the slurry can be formed by combining any or all of the previously described slurry components with mixing media in a container.
  • the mixture can be mixed using conventional techniques known to those skilled in the art such as shaking with up to about a 1 inch (about 25.4 mm) diameter alumina or zirconia mixing media, ball milling using about a 0.25 inch to about a 1 inch (about 0.64cm to about 2.54cm) diameter alumina or zirconia mixing media, attritor milling using about a 1mm to about a 5mm diameter zirconia-based mixing media, planetary ball milling using from about a 1mm to about a 5mm diameter zirconia-based media, or mechanical mixing or stirring with simultaneous application of ultrasonic energy.
  • the mixing media or ultrasonic energy can break apart any agglomerated ceramic particles in the slurry. Any mixing media present may then be removed by straining, for example.
  • thickener may be added to the slurry if desired and the resulting mixture may be agitated by such methods as mechanical stirring, rolling, blending, shaking, and other like methods until the thickener is fully dissolved, generally after about 5 to about 60 minutes.
  • the addition of the sintering aids may follow along with mixing using the previously described methods until the sintering aids dissolve, which is about 5 to about 60 minutes.
  • the slurry can be filtered through screens of varying mesh sizes to remove any impurities that may be present, such as after the initial mixing of the slurry or after use of the slurry to deposit coating layers.
  • a 325 mesh screen for example, can be used to filter out impurities having an average size of about 44 microns or greater.
  • the slurry can be agitated indefinitely by slow rolling, slow mechanical mixing, or other like methods to avoid trapping air bubbles in the slurry.
  • the slurry may be refreshed by adding additional solvent to account for that which has evaporated during processing.
  • the slurry can be set aside until needed for application.
  • masking can be applied to the ceramic component before the slurry is applied to prevent coating specific areas of the component.
  • Masking may be carried out using conventional techniques known to those skilled in the art including, but not limited to, tapes, tooling, and paint-on adhesives.
  • the slurry can be applied to the component to produce a coated component.
  • the slurry can be applied to the component (or on top of a previously applied layer) using any conventional slurry deposition method known to those skilled in the art, including but not limited to, dipping the component into a slurry bath, or painting, rolling, stamping, spraying, or pouring the slurry onto the component. Slurry application can be carried out manually or it may be automated.
  • the coated component can be dried. Drying may be carried out in an enclosed area having additional organic solvent present in secondary containers. This can help slow the drying process because the atmosphere can be saturated with organic solvent. Since this process utilizes an organic solvent, it is not strongly sensitive to humidity. Temperature variation can be used to control the drying rate, however, those skilled in the art will understand that temperatures can be kept below the flash point of the organic solvent. Placing a coated component in a vacuum chamber and pulling a vacuum can also be used to accelerate drying.
  • burnout of the organic processing aids may be carried out by placing the dried component in an elevated temperature environment so that any residual solvent can be evaporated and the organic processing aids can be pyrolyzed.
  • burnout of the organic processing aids may be accomplished by heating the dried component at a rate of from about 1°C/min to about 15°C/min to a temperature of from about 400°C to about 1000°C and holding the component at this temperature for from about 0 to about 10 hours.
  • the coated component may be heated at a rate of from about 2°C/min to about 6°C/min to a temperature of from about 600°C to about 800°C and holding the component at this temperature for from about 0 to about 10 hours.
  • the dried component may then be sintered to produce a component comprising an environmental barrier coating.
  • Sintering can serve to simultaneously densify and impart strength to the coating. Additionally, in the case of the transition and compliant layers of the EBC, sintering can impart a hermetic seal against high temperature steam present in the engine environment. In the case of the outer layer, sintering can provide a dense barrier against the infiltration of molten silicates, such as calcium-magnesium aluminosilicate (CMAS) that may be encountered as a result of particulate contamination (i.e. dirt and sand) in the engine environment. Sintering can be carried out using a conventional furnace, or by using such methods as microwave sintering, laser sintering, infrared sintering, and the like.
  • CMAS calcium-magnesium aluminosilicate
  • Sintering can be accomplished by heating the dried component at a rate of from about 1°C/min to about 15°C/min to a temperature of from about 1100°C to about 1700°C and holding the component at that temperature for from about 0 to about 24 hours.
  • sintering can be accomplished by heating the coated component at a rate of from about 5°C/min to about 15°C/min to a temperature of from about 1300°C to about 1375°C and holding the component at that temperature for from about 0 to about 24 hours.
  • sintering can occur rapidly by placing the coated component into a furnace heated to a temperature of from about 1000°C to about 1400°C.
  • all layers of the EBC can be applied, one on top of the other, before masking removal, organic processing aid burnout, and sintering are carried out.
  • the layer should be dried, or partially dried, before the application of the subsequent layer.
  • Binder burnout and sintering heat treatments may be carried out in an ambient air atmosphere, or in an inert gas atmosphere where the inert gas is selected from hydrogen, a noble gas such as helium, neon, argon, krypton, xenon, or mixtures thereof.
  • the inert gas atmosphere can be used in conjunction with Lnb and SiO 2 sintering aids so as not to convert the rare earth metal to an oxide before it melts. Maintaining the Lnb metal in a metal state can promote liquid phase sintering and subsequent reaction with the SiO 2 .
  • Infiltration may allow for the densification of a thicker layer of EBC material at one time. Moreover, infiltration is a way to add more sintering aid after sintering if the coating is not as dense as desired.
  • the sol-gel solution used for infiltration may be a solution of an organic solvent and a solvent soluble salt sintering aid, as defined previously, or a solution of water and a water soluble salt sintering aid.
  • the secondary material when the secondary material is highly volatile in high temperature steam, such as but not limited to, alkali silicates, alkaline earth silicates, mullite, iron silicate, borosilicate glass, nickel silicate, and residual sintering aids of iron, aluminum, titanium, gallium, nickel, boron, alkali, and alkali-earth compounds, as long as the total volume of secondary material, plus porosity (plus residual sintering aid when present) in either of the intermediate layer or compliant layer (when present) of the EBC remains about 15% by volume or less, the hermetic seal can be maintained.
  • EBC embodiments described herein can offer a variety of benefits over current EBCs and manufacturing processes thereof.
  • the inclusion of a sintering aid in the EBC embodiments herein can permit sintering at lower temperatures (i.e. about 1357°C or below). This can result in a highly dense (i.e. greater than about 85% for the transition layer, and greater than about 70% for each of the outer, and compliant, layers) coating that can be less susceptible to the penetration of hot steam from the engine environment, and can also help prevent the degradation of the mechanical properties of the underlying component that could result from prolonged exposure to higher temperatures.
  • the solids loading of primary material ceramic particles in the repair slurry can be greater than about 30% to about 55% by volume (as opposed to greater than about 10% by volume in one embodiment of the original slurry, and from about 10% to about 55% by volume in another embodiment of the original slurry used to make the layer).
  • the repair slurry may be applied using any conventional method including those described previously, and the resulting "repair(ed) coating" may then be processed as described previously herein before application of any subsequent layer of the EBC.
  • repairs may include fixing defects after application and sintering of the entire EBC.
  • the repair may be carried out on the EBC having defects using a transition layer repair slurry comprising the same materials present in the previously defined transition layer slurry (i.e. primary transition material, a sintering aid, and optionally secondary material).
  • This particular repair slurry can seep into any defects present in the EBC and provide a hermetic seal to the repaired EBC coating after sintering.
  • the solids loading of the transition layer repair slurry may comprise upwards of about 30% to 55% by volume.
  • transition layer slurry or outer layer slurry can comprise a thickness of at least about 0.5 mils, and in another embodiment from about 0.5 mils to about 3 mils.
  • the applied transition layer slurry can then be processed as described previously to produce a repaired EBC having an acceptable surface roughness. Additional slurry layers may be applied to the EBC if desired.
  • Such repair processes can provide the ability to repair localized defects, at varying points during the application or life of the coating, as opposed to stripping off and reapplying the entire coating. This, in turn, can result in a savings of time, labor, and materials.
  • Example 1 A silicon bond coat was applied to a SiC-SiC CMC using a conventional air plasma spray process.
  • a primary transition material slurry was made by first mixing ytterbium disilicate (primary transition material), iron oxide nanoparticles (sintering aid), ethanol (solvent), and polyethylenimine (dispersant) in a plastic container, along with enough 0.25 inch (6.35mm) diameter, spherical zirconia media to line the bottom of container. This mixture was placed on a roller mill for 15 hours. After taking the container off of the roller mill, the zirconia media was removed and the slurry was filtered through a 325 mesh screen to remove any large particle agglomerates.
  • a primary outer material slurry was made by first mixing ytterbium monosilicate (primary outer material), iron oxide nanoparticles (sintering aid), ethanol (solvent), and polyethylenimine (dispersant) in a plastic container, along with enough 0.25 inch (6.35mm) diameter, spherical zirconia media to line the bottom of container. This mixture was placed on a roller mill for 15 hours. After taking the container off of the roller mill, the zirconia media was removed and the slurry was filtered through a 325 mesh screen to remove any large particle agglomerates.
  • the resulting primary outer material slurry consisted of 61.19% ytterbium monosilicate, 0.29% iron oxide, 0.61% polyethylenimine, and the balance ethanol (all percents by weight).
  • the silicon and transition layer-coated ceramic component was dipped into Slurry B, dried in ambient conditions, re-dipped into Slurry B, dried in ambient conditions, and heat-treated at 10°C/minute to 1000°C to burn out any residual organic materials. Then, the temperature was increased at 10°C/minute from 1000°C to 1344°C and held for 10 hours to densify the transition layer. After heat treatment, the layer comprised iron-doped yttrium monosilicate. The entire heat treatment was carried out in air. The heating environment resulted in the transition layer having a porosity of less than 15% by volume. The dipping, drying, and heat treatments were repeated 2 times to build thickness of the outer layer.
  • FIG. 2 shows a SEM micrograph of this coating microstructure with the air plasma spray silicon bond coat (100), a thin silica layer (3.9 micrometers) (102), transition layer (104), and outer layer (106).
  • the outer layer and transition layer appeared to consist only of iron-doped primary materials (iron-doped ytterbium monosilicate and iron-doped ytterbium disilicate, respectively), x-ray diffraction was not able to detect any secondary material present in the EBC.
  • EDS analysis of the layers suggested that the iron oxide had dissolved into the primary materials.
  • Example 3 To demonstrate proof of principle, a primary transition layer was deposited on a silicon metal wafer using a slurry deposition process.
  • a primary transition material slurry was made by first mixing ytterbium disilicate powder (primary transition material), gallium oxide powder (sintering aid), ethanol (solvent), and polyethylenimine (dispersant) in a plastic container, along with enough 0.25 inch (6.35mm) diameter, spherical zirconia media to line the bottom of container. This mixture was placed on a roller mill for 15 hours. After taking the container off of the roller mill, the zirconia media was removed and the slurry was filtered through a 325 mesh screen to remove any large particle agglomerates.
  • the heating environment resulted in the transition layer (108) having a porosity of less than 15% by volume as shown in FIG. 4 .
  • No secondary phases were observed in this coating via electron microscope examination. EDS analysis suggested that the gallium had dissolved into the ytterbium disilicate primary material.

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